Roofing



G. KNAPP A ril 5, 1938.

ROOFING Original Filed April 9, 1930 3 Sheets-Sheet l R Y N H w m o V m HWWWMWW m H 0 T o m Q W A N V k z o o M. o w M o Q & w

April 5, 1938.

G KNAPP 2, 12,8

ROOFING Original Filed April 9, 1930 3 Sheets-Sheet 2 24 I6 Georgy, W INVENTOR A TTORNEY' April 5, 1938. G. KNAPP 2,112,898

ROOFING Original Filed-April 9, 1930 3 Sheets-Sheet 3 Q /6 INVENTOR BY WM d 5% ATTORNEY Patented Apr. 5,1938

UNITED STATES ROOFING George Knapp, St. Louis, Mo., assignor to Certain-teed Products Corporation Application April 9, 1930, Serial No. 442,764 Renewed October 10, 1936 -15 Claims.

This invention relates to the art of composition roofing and has for an object the production of a new type of ornamental roofing material which may be adapted for use as a siding where an ornamental efiect or constructional limitation is desired.

Another object of the invention is the provision of a new process for obtaining the type of roofing or siding material described above at minimum production cost and with the minimum amount of materials compatible with the production of a structurally satisfactory product.

The invention includes matter which is an improvement on the process disclosed in the patent to Outman, No. 1,426,497 dated August 22, 1922.

Other objects and advantages of the present invention will hereinafter appear when reference is had to the accompanying specification and drawings, wherein is illustrated one exemplary embodiment of my invention.

In the drawings, Figure 1 is a diagrammatic view, in elevation, of the apparatus by which the new process is carried out, intermediate parts of the apparatus being omitted.

Figure 2 is a plan view of part of the apparatus shown in Figure 1.

Figure 3 is a plan view of a sheet of one type of composition roofing or siding material as it appears at one stage of the process herein disclosed.

Figure 4 is a plan view of an element which can be produced by the invention.

Fig. 5 is a plan view of a fragment of a roof or siding showing how the type of element shown 5 in Figure 4 can be laid or placed to give the effect of a brick construction.

Figure 6 is a modified form of element obtainable by virtue of this invention.

Figure '7 illustrates the manner in which the element illustrated in Figure 6 can be cut from a sheet processed as herein disclosed.

' Figure 8 is a transverse sectional view of a single element showing the particular structure obtained by the practice of this invention.

Figure 9 is a transverse sectional view of two of the elements illustrated in Figure 8, disposed in overlapping arrangement.

Referring now to Figure 1, reference character I represents a sheet of fibrous material such as is ordinarily used in the production of composition roofing. This sheet is preferably preimpregnated with a bituminous saturant in order to strengthen it and render it thoroughly waterproof. The sheet is led across rollers 2 in order 55 to direct it to the mechanism which is to apply the bituminous coating hereinafter to be. described. In the instance typified, the sheet I is led between rollers 5 and 6 suspended above tank 3, whereby the underside of the sheet is coated with a bituminous material 4 of high melting point and highly viscous at ordinary temperatures. This material is preferably applied while hot as it is more easily handled in this condition. Lower roller 5 revolves in the material 4 and transfers a uniform layer thereof 10 to the underside of sheet I and presses it thereon 'between rollers 5 and 6.

If desired, the application of the bituminous coating 4 can be made by passing the sheet under a hopper which deposits a uniform layer 15 of the material thereon, and thence to a pair of squeeze rolls which uniformly spreads the material on the sheet, or the sheet may be run into the tank on a partly submerged roller which keeps one side free from the coating material.

After receiving the bituminous coating &, the coated sheet is passed over cylinder I against I which scraping mechanism 8, including-scraper 8', is forced. The mechanism is designed and adjusted so that a considerable part of the coat- 25 ing l is scraped ofi the sheet in pre-determined areas. In the instance typified the scraping mechanism is arranged to scrape off relatively wide areas 8" in order to give the desired ultimate result. The entire thickness of coating is 30 not, of course, scraped off as it is desirable to have some coating material on the sheet for protection against weather.

After the scraping operation the sheet is led back over roller 6 and between pressure rolls ll and I2 where a layer of grit surfacing l0, distributed on the sheet through hopper I0, is partially embedded in the bituminous coating throughout the areas which have not been scraped. If. desired a hopper 9 can be placed above the sheet before it is led under hopper Ill and fine granules of differently colored material, such as slate dust, can be spread on areas 8" through orifices 9" in hopper 9, thus preventing any of the surfacing material Ill from sticking to areas 8". The latter provision is not, however, a part of this invention but is the invention of Winfred H. Outman as disclosed and claimed in his application, Serial No. 540,- 846, said application having a common assignee 5 with this present application. The areas 8" will hereinafter be referred to as unsurfaced whether or not covered with the fine granules mentioned above. These granules, when applied, are so fine that they do not serve as a true surfacing l.

After the grit surfacing has been pressed into the coating in the desired areas, the roofing sheet is passed aroimd a number of cooling rolls II and I3 and then festooned over a series of looper rollers (not shown). I

While the material is still warm it is led between cylinders H and I which are provided with lugs sharp-edged l4 and complementary recesses l5 which cut out areas l6 as indicated in Figure 3. These cut out portions extend in the instance typified, completely across coated areas I. and slightly overlap into the noncoated or bare portions 8" but it is not essential that these cut outs extend exactly as shown.

slitting discs I! and I8 are provided to slit the material at I! so as to divide the sheet into a number of strips, in the embodiment shown in Figure 3, four are shown. In this embodiment, the slits l9 fall alternately in the middle of the surfaced portions l0 and in the middle of the center unsurfaced portion 8". Transverse cuts 22 are thereafter made in order to produce elements 23 similar to that shown in Figure 4. These elements of elongated shape are provided by reason of the-nature of the cuts made, with a number of tabs separated by slots or cut-outs it, each tab being substantially coated with a relatively thick bituminous coating and surfaced with granular material ID. The remaining areas 8" present a smooth un-surfaced appearance, being covered with a relatively thin film or coat of bituminous coating material which in practice is generally dark in color. If the fine grit particles described above areused the areas 8" may have an outer film of these fine particles; in such case these particles are preferably of a color contrasting with that of the surfacing It for the purpose hereinafterto be described. The construction is shown clearly in Figure 8.

The elements 23 may be laid on the surface to be protected in the manner indicated in Figure 5. when so laid areas l0 stand out by virtrue of their being outlined in the contrasting color of the areas 8'', which appear as mortar joints between bricks. Through each cut out portion I6 is disclosed part of the underlying area 8" which is the same color as portions 24 of the adjacent overlying course. Thus each surfaced tab is completely surrounded by a narrow strip of differently colored material, accentuating the surfaced portions of each tab and creating a realistic illusion of bricks laid in mortar. Moreover each surfaced portion being built upon a thick bituminous coating, these areas will stand out in relief as indicated in Figure 9,

creating the shadow effect so much desired in roofing or siding material.

If desired, cutters ll may be so arranged that they will cut'notches closer together on the sheet, thereby conditioning the sheet for division into elements which will simulate bricks laid endwise. 'Ihese'elements, when laid, can be suitably interspersed with the regularly appearing brick simulations in order to present the staggered appearance generally used in brick construction.

The invention is not to be limited to the brickeffect product shown and described above as an exemplary embodiment but may be utilized in various other ways. Any desired design can be made by utilizing the broad principle of proanaaoa surfacing but merely render the scraped areas smooth and incapable ofadhering to granular ducing a compositioncovering element with certain areas surfaced and coated with a normally thick coating, and certain other areas in the pattern unsurfaced and only coated with a relatively thin coating. Figures 6 and 7 illustrate a different pattern eflect which may be obtained by the use of the invention. Instead of cutting notches as shown in Figure 3 the outline illustrated in Figure 7 may be cut and elements produced which can be laid as illustrated in Figure 6. e

If desired, in making the imitation brick design illustrated in Figures 2, 3, 4 and 5, a mat or tapestry brick effect can be obtained by the provision of a series of hoppers I 0 each carrying a different colored grit. By the provision of suitable valves in these hoppers the flow of grit from onejhopper can be so timed that it will occur only during an interval necessary to dis-- tribute grit of the desired color to an individual brick-simulating space. The discharge from the other hoppers is cut off during this interval and is thereafter allowed to occur, one by one,

at times during which the fiow from the hoppers carrying the other colored grit is shut off. In this manner is deposited a series of areas of differently colored grit, the deposit of such areas being so timed as to coincide with the division of such areas by cut-outs l6.

Having thus described my invention, I claim:

1. A covering element for laying in courses in overlapp arrangement comprising a base sheet, a continuous adhesive coating upon the surface of said sheet, said coating having-in the portion thereof to be exposed in the overlapping arrangement a thickness capable of binding upon 'the surface thereof a layer of granular surfacing material, said coating in the portion thereof to be overlapped by an element in a superimposed course having a reduced thickness and having a texture of surface simulating the surface of masonry joints, a layer of said granular surfacing material adhering to said portion of the coating to be exposed, said portion of the coating of reduced thickness having an extent sufficient to completely underlie the portion to be exposed of an element in a superimposed course and to expose a narrow band of said coating of reduced thickness between said portion of the element surfaced with granular material and the edge to be exposed of said superimposed element.

2. A covering element for laying in courses in overlapping arrangement comprising a base sheet, a continuous coating of mastic material upon the surface of said sheet, said coatinghaving the portion thereof to be overlapped by an element in a superimposed course scraped to provide a surface having a texture simulating that of the surface of masonry joints, said scraped portion of the coating being of reduced thickness and having an extent sufficient to completely underlie the portion to be exposed of an element in a superimposed course and to ex pose a narrow band of said scraped portion of the coating between the portion to be exposed of the element and the edge to be exposed of said superimposed element. v

3. A covering element for laying in courses in overlapping arrangement comprising a base sheet, a continuous coating of mastic material upon the surface of said sheet, said coating having in the portion thereof to be exposed in the overlapping arrangement a thickness capable of binding upon the surface thereof a layer of granular surfacing material of a character and grain size to simulate the surface of masonry units, said coating in the portion thereof to be overlapped by an element in a superimposed course being of reduced thickness and being scraped to provide a surface having a texture simulating that of the surface of masonry joints, a layer of said granular surfacing material adhering to said portion of the coating to be exposed, said scraped portion of the coating having an extent sufficient to completely underlie the portion to be exposed of an element in a superimposed course and to expose a narrow band of said scraped portion of the coating between said portion of the element surfaced with granular material and the edge to be exposed of said superimposed element, said portion of the element surfaced with granular material being divided by cut-outs in the base sheet transversely to the edge to be exposed thereof into areas simulating the masonry units.

4. An element for laying in courses in overlapping arrangement comprising a base sheet, a continuous mastic coating upon the surface of said sheet, said sheet having the portion to be exposed thereof divided by cut-outs in the base into areas simulating masonry units, said coating having the portion thereof to be overlapped scraped to provide a texture of surface simulating the texture of the surface of masonry joints, said scraped portion of the coating being of reduced thickness and having an extent sufficient to completely underlie the cut-outs of the portion to be exposed of an element in a superimposed course, said cut-outs exposing in the overlapping arrangement areas of said scraped surface simulative of the masonry joints.

5. A covering for a surface comprising a plurality of elements laid in courses in overlapping arrangement, said elements having a continuous adhesive coating applied upon the surface of a base sheet, said coating on the exposed portions of the elements in the overlapping arrangement having a thickness capable of binding upon the surface thereof a layer of granular surfacing material, said coating in the portion thereof to be overlapped by the element in a superimposed course having a reduced thickness, a layer of said granular surfacing material adhering to said portions of the coating to be exposed, said portions of the coating of reduced thickness having an extent sumcient to completely underlie the portion to be exposed of the element in the superimposed course and to expose narrow bands of said coating of reduced thickness between said portions of the elements surfaced with granular surfacing material and the edges to be exposed of said superimposed elements.

6. A covering for surface comprising a plurality of elements lr id in courses in overlapping arrangement, said elements having a continuous mastic coating applied upon the surface of a base sheet, said coating on the exposed portions of the elements in the overlapping arrangement having thereon a layer of granular surfacing material, said coating having the portion thereof to be overlapped by an element in the superimposed course scraped to provide a surface of a texture simulating the surface of masonry joints, said scraped portions of the coating being of reduced thickness and having an extent sufficient to completely underlie the portion to be exposed of an element in the superimposed course and to expose narrow bands of said scraped coating between said portions of the elements surfaced with granular surfacing material and the edges to be exposed of said superimposed elements.

7. A covering for a surface comprisinga plurality of elements laid in courses in overlapping arrangement, said elements having a continuous mastic coating applied upon the surface of a base sheet, said coating having the portion thereof to be overlapped scraped to provide a surface of a texture simulating the surface of masonry joints, said scraped portions of the coating being of reduced thickness and having an extent suflicient to completely underlie the portionto be exposed of an element in the superimposed course, said portions to be exposed of the elements being divided by cut-outs in the base into areas simulating masonry units, said cutouts exposing in the overlapping arrangement said scraped surfaces to present between the areas simulating the masonry units surfaces simulative of the surface of masonry joints.

8. A covering element for laying in courses in overlapping arrangement comprising a base sheet having a longitudinal edge, a continuous coating of adhesive material upon the surface of said sheet, said base having spaced cut-outs extending transversely to said longitudinal edge, said coating upon the portions of the surface thereof adjacent said longitudinal edge and between said cut-outs being surfaced with a layer of granular material of a character to simulate the surface of a masonry unit, the transverse dimensions of said areas surfaced with granular material being such as to simulate the depth of masonry units, the length of the cut-outs transversely of said longitudinal edge being at least equal to said transverse dimension of said surfaced areas, the thickness of the coating upon the remaining portion of said base being reduced with respect to that upon said surfaced areas, said coating of reduced thickness having a character and texture of surface simulating the surface of masonry joints.

9. A covering element for laying in courses in overlapping arrangement comprising a base sheet having a longitudinal edge, a continuous coating of adhesive material upon the surface of said sheet, said base having spaced cutouts extending transversely to said longitudinal edge, said coating upon the portions of the surface thereof adjacent said longitudinal edge and between said cut-outs being surfaced with a layer of granular material of a character to simulate the surface of a masonry unit, the transverse dimensions of said areas surfaced with granular material being such as to simulate the depth of masonry units, the length of the cut-outs transversely of said longitudinal edge being at least equal to said transverse dimension of said surfaced areas, the thickness of the coating upon the remaining portion of said base being reduced with respect to that upon said surfaced areas, said coating of reduced thickness having a character and texture of surface simulating the surface of masonry joints, the dimension of said remaining portion of the element transversely of said longitudinal edge being not less than the simulated depth of the masonry unit plus the width of a longitudinal joint of the masonry adjacent thereto.

10. A covering for a surface. to simulate a masonry construction comprising a plurality of elements of the type defined in claim 9 arranged with said remaining portion of the element in one course underlying the surfaced areas and the cut-outs therebetween of the elements of a superadjacent course but with a narrow band of said remaining portion exposed below the longitudinal edge of said superadjacent element and with areasof said remaining portion exposed through but completely behind said cut-outs.

11. A covering element for laying upon a surface in an assembly of similar elements in courses comprising a base sheet, a continuous coating of adhesive material upon the surface of said sheet, said coating upon a portion of element removed from one edge of the element having a thickness reduced with respect to that upon the portion of the element lying between said portion of reduced thickness and said edge, said portion of the coating of reduced thickness providing a texture of its surface simulating the surface of masonry joints and having an extent sufficient to be exposed as a narrow band below the super-adjacent course in the assemblyto simulate the joint of a masonry construction.

12. A covering element for laying upon a surface in an assembly of similar elements in courses, said element being formed of sheet material and having an edge, intended to be exposed and to extend in the coursewise direction, said sheet comprising a continuous layer of mastic material a portion of which removed from said edge thereof has its thickness reduced with respect to that of the portion of said layer lying between said portion of reduced thickness and said edge, said portion of reduced thickness providing a texture of its surface simulating the surface of masonry joints and having an extent sufficient to be exposed as a narrow band below the superadiacent course in the assembly to simulate the joint of a masonry construction.

13. A covering for a surface to simulate a out.

masonry. construction comprising a plurality of elements of the type defined in claim 12 arranged with said portion of reduced thickness of the element of one course underlying that portion of a superadjacent element which lies between the portion of reduced thickness and said edge in said superadjacent element but with a narrow band of said portion of reduced thickness of the underlying element exposed below said edge of said superadjacent element.

14. A covering element for laying upon a surface in an assembly of elements in courses in overlapping arrangement, said element comprising a layer of mastic material, a portion of said layer being scraped to provide upon the part of said element which is overlapped by a super-. posed course a reduced thickness of said layer.

v 15. A covering element for laying in courses in overlapping arrangement comprising a base sheet having a longitudinal edge, a continuous coating of adhesive upon the surface of said sheet,

said base having a cut-out therein extending transversely to said longitudinal edge, said coating upon the portions thereof adjacent said edge and at. either side of the cut-out being surfaced with a layer of granular material, the inner boundary of said surfaced portions being located adjacent the inner end of the cut-out, the thickness of the coating upon the portion of said base beyond said surfaced portions being reducedv with respect to that upon said surfaced portions and having an extent in said transverse direction not substantially less than the length of the cut- GEORGE KNAPP. 

